U.S. patent number 11,342,807 [Application Number 16/483,809] was granted by the patent office on 2022-05-24 for motor and pump device.
This patent grant is currently assigned to NIDEC SANKYO CORPORATION. The grantee listed for this patent is NIDEC SANKYO CORPORATION. Invention is credited to Masaki Harada, Nobuki Kokubo, Hiroki Kuratani, Takashi Yamamoto.
United States Patent |
11,342,807 |
Harada , et al. |
May 24, 2022 |
Motor and pump device
Abstract
A motor may include a rotor provided with a rotating shaft that
protrudes to a first side in an axial direction; a stator disposed
on an outer peripheral side of the rotor; a resin sealing member
that covers the stator; and a cover member that is disposed on the
first side of the resin sealing member and supports the rotating
shaft. The cover member may include a plurality of gate marks
disposed at different angular positions and a plurality of ribs
that protrude to a second side in the axial direction. The ribs may
be disposed at positions where each midpoint between the gate marks
adjacent to each other in the circumferential direction overlap
with an axis of the rotor.
Inventors: |
Harada; Masaki (Nagano,
JP), Kuratani; Hiroki (Nagano, JP),
Yamamoto; Takashi (Nagano, JP), Kokubo; Nobuki
(Nagano, JP) |
Applicant: |
Name |
City |
State |
Country |
Type |
NIDEC SANKYO CORPORATION |
Nagano |
N/A |
JP |
|
|
Assignee: |
NIDEC SANKYO CORPORATION
(Nagano, JP)
|
Family
ID: |
1000006327534 |
Appl.
No.: |
16/483,809 |
Filed: |
February 7, 2018 |
PCT
Filed: |
February 07, 2018 |
PCT No.: |
PCT/JP2018/004140 |
371(c)(1),(2),(4) Date: |
August 06, 2019 |
PCT
Pub. No.: |
WO2018/150967 |
PCT
Pub. Date: |
August 23, 2018 |
Prior Publication Data
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|
|
Document
Identifier |
Publication Date |
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US 20200195080 A1 |
Jun 18, 2020 |
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Foreign Application Priority Data
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|
|
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Feb 14, 2017 [JP] |
|
|
JP2017-024967 |
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
H02K
15/14 (20130101); H02K 21/16 (20130101); H02K
5/16 (20130101); F04D 29/40 (20130101); H02K
5/08 (20130101); F04D 29/18 (20130101); H02K
7/14 (20130101); F04D 13/06 (20130101) |
Current International
Class: |
H02K
5/08 (20060101); H02K 5/16 (20060101); H02K
15/14 (20060101); H02K 21/16 (20060101); H02K
7/14 (20060101); F04D 29/18 (20060101); F04D
13/06 (20060101); F04D 29/40 (20060101) |
Field of
Search: |
;310/86 |
Foreign Patent Documents
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|
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|
|
|
|
2007023877 |
|
Feb 2007 |
|
JP |
|
2008109848 |
|
May 2008 |
|
JP |
|
2012151981 |
|
Aug 2012 |
|
JP |
|
2013245658 |
|
Dec 2013 |
|
JP |
|
2014230361 |
|
Dec 2014 |
|
JP |
|
2016003580 |
|
Jan 2016 |
|
JP |
|
Other References
Oxford Languages;
https://www.google.com/search?q=midpoint+dictionary&rlz=1C1GCEB_enUS792US-
792&oq=midpoint&aqs=chrome.0.69i59j0i433i512j69i57j0i433i512j0i512j0i433j0-
i131i433i512j0i457i512j0i512j46i175i199i512.2288j0j4&sourceid=chrome&ie=UT-
F-8 (Year: 2021). cited by examiner .
International Search Report corresponding to Application No.
PCT/JP2018/004140; dated Apr. 24, 2018. cited by applicant.
|
Primary Examiner: Kenerly; Terrance L
Attorney, Agent or Firm: Cantor Colburn LLP
Claims
The invention claimed is:
1. A motor comprising: a rotor provided with a rotating shaft that
protrudes to a first side in an axial direction; a stator disposed
on an outer peripheral side of the rotor; a resin sealing member
that covers the stator; and a cover member that is disposed on the
first side of the resin sealing member and supports the rotating
shaft; wherein the cover member comprises a plurality of gate marks
disposed at different angular positions and a plurality of ribs
that protrude to a second side in the axial direction, and the ribs
are disposed at positions where each midpoint between the gate
marks adjacent to each other in the circumferential direction
overlap with an axis of the rotor, wherein the cover member
comprises a cover member side securing surface that faces, in the
axial direction, a resin sealing member side securing surface
provided on the resin sealing member, the cover member side
securing surface is secured to the resin sealing member side
securing surface via an adhesive agent layer, and the cover member
side securing surface is positioned on a same plane as tip surfaces
of the plurality of ribs.
2. The motor according to claim 1, wherein the plurality of gate
marks is annularly disposed around the rotating shaft, and the
plurality of ribs extends in a radial direction around the rotating
shaft.
3. The motor according to claim 1, wherein a first adhesive agent
reservoir portion which recesses on the first side is provided
between adjacent ribs of the plurality of ribs.
4. The motor according to claim 3, wherein the first adhesive agent
reservoir portion is shaped as a hollow shape of the cover
member.
5. The motor according to claim 3, wherein the cover member side
securing surface is provided with a chamfered surface formed on an
edge which is adjacent to the first adhesive agent reservoir
portion.
6. The motor according to claim 1, wherein each rib of the
plurality of ribs comprises a chamfered surface formed on an edge
of a tip surface facing the second direction.
7. The motor according to claim 1, wherein the cover member side
securing surface and the resin sealing member side securing surface
are provided on the entire circumference.
8. The motor according to claim 1, wherein the ribs and the gate
marks are each disposed at equal angular intervals.
9. A motor comprising: a rotor provided with a rotating shaft that
protrudes to a first side in an axial direction; a stator disposed
on an outer peripheral side of the rotor; a resin sealing member
that covers the stator; and a cover member that is disposed on the
first side of the resin sealing member and supports the rotating
shaft; wherein the cover member comprises a plurality of gate marks
disposed at different angular positions and a plurality of ribs
that protrude to a second side in the axial direction, and the ribs
are disposed at positions where each midpoint between the gate
marks adjacent to each other in the circumferential direction
overlap with an axis of the rotor, wherein the cover member
comprises a protrusion portion that protrudes on the second side
and covers an outer peripheral side of the resin sealing member, an
engagement protrusion portion is provided on the outer peripheral
surface of the resin sealing member, and the protrusion portion
comprises a rotation engagement portion that engages the engagement
protrusion portion as a result of the cover member being rotated
around the rotating shaft in a state where the cover member is
making contact with the resin sealing member in the axial
direction.
10. A pump device comprising: a motor comprising: a rotor provided
with a rotating shaft that protrudes to a first side in an axial
direction; a stator disposed on an outer peripheral side of the
rotor; a resin sealing member that covers the stator; and a cover
member that is disposed on the first side of the resin sealing
member and supports the rotating shaft; wherein the cover member
comprises a plurality of gate marks disposed at different angular
positions and a plurality of ribs that protrude to a second side in
the axial direction, and the ribs are disposed at positions where
each midpoint between the gate marks adjacent to each other in the
circumferential direction overlap with an axis of the rotor; and an
impeller attached to an end portion of the rotating shaft which
passes through the cover member and protrudes on the first side of
the cover member, wherein the cover member comprises a cover member
side securing surface that faces, in the axial direction, a resin
sealing member side securing surface provided on the resin sealing
member, the cover member side securing surface is secured to the
resin sealing member side securing surface via an adhesive agent
layer, and the cover member side securing surface is positioned on
a same plane as tip surfaces of the plurality of ribs.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
This is the U.S. national stage of application No.
PCT/JP2018/004140, filed on Feb. 7, 2018. Priority under 35 U.S.C.
.sctn. 119(a) and 35 U.S.C. .sctn. 365(b) is claimed from Japanese
Application No. 2017-024967, filed Feb. 14, 2017; the disclosures
of which are incorporated herein by reference.
TECHNICAL FIELD
At least an embodiment of the present invention relates to a pump
device and a motor used for the pump device.
BACKGROUND
Patent Literature 1 discloses a pump device that rotates an
impeller by means of a motor. The motor used in the pump device of
Patent Literature 1 includes a rotor and a stator disposed on the
outer peripheral side of the rotor, wherein the stator is covered
and sealed with a BMC resin. A case member (upper case) that forms
a pump chamber is secured by screws to a resin sealing member
covering the stator. The stator includes a stator core, an
insulator, and a coil wire wound around the insulator. The coil
wire is connected to a connector for external connection through a
substrate. In the connector, a connection portion with the
substrate is covered with the resin sealing member, but a terminal
for external connection protrudes in the radial direction from an
outer peripheral surface of the resin sealing member.
CITATION LIST
[Patent Literature 1] Japanese Unexamined Patent Application
Publication No. 2016-3580
In the motor described in Patent Literature 1, the case member
(upper case) constituting the pump chamber is secured by screws to
the resin sealing member. However, securing by screws requires the
use of a securing screw, and it is necessary to provide a screw
securing portion in the upper case and in the resin sealing member.
Therefore, the number of parts is large and the structure is
complicated. If an adhesive agent is used for bonding purposes
without using a screw, for example, bonding can be achieved as a
result of interposing an adhesive agent on a part where the upper
case and the resin sealing member make contact in the axis line
direction of the motor.
Here, if the upper case is a resin molded article, a hollow shape
is provided to ensure the molding properties are adequate. However,
if a hollow shape is provided, the contact area with the resin
sealing member decreases. Therefore, if an adhesive agent is used
for bonding purposes, there is a concern that the bonding strength
may decrease because the area to which the adhesive agent can be
applied becomes smaller. Furthermore, there is a concern that the
strength of the upper case may decrease as a result of providing a
hollow shape.
SUMMARY
In view of the above problems, at least an embodiment of the
present invention ensures, in a motor which includes a resin
sealing member that covers a stator, the strength of a cover member
secured to the resin sealing member.
In order to solve the above problems, a motor of at least an
embodiment of the present invention includes: a rotor provided with
a rotating shaft that protrudes on a first side in an axis line
direction; a stator disposed on an outer peripheral side of the
rotor; a resin sealing member that covers the stator; and a cover
member disposed on the first side of the resin sealing member and
supports the rotating shaft; wherein the cover member includes a
plurality of gate marks disposed at different angular positions and
a plurality of ribs that protrude on a second side in the axis line
direction, and the ribs are disposed at positions where each
midpoint between the gate marks adjacent to each other in the
circumferential direction overlap with the axis line.
In the motor of at least an embodiment of the present invention, a
resin molded article is used as the cover member secured to the
resin sealing member, and ribs are formed on the cover member at
positions that overlap with each midpoint of adjacent gate marks in
the axis line direction. In this manner, locations (weld lines) at
which resin flowing in from adjacent gates merge at the time of
molding the cover member can be reinforced by the ribs. As a
result, the strength of the cover member can be ensured.
In at least an embodiment of the present invention, it is desirable
that the plurality of gate marks is annularly disposed around the
rotating shaft, and the plurality of ribs extends in the radial
direction around the rotating shaft. In this manner, the ribs can
be disposed along the weld lines. Therefore, the strength of the
cover member can be ensured.
In at least an embodiment of the present invention, it is desirable
that the cover member includes a cover member side securing surface
that faces, in the axis line direction, a resin sealing portion
side securing surface provided on the resin sealing portion, the
cover member side securing surface is secured to the resin sealing
portion side securing surface via an adhesive agent layer, and the
cover member side securing surface is positioned on the same plane
as the tip surfaces of the plurality of ribs. In this manner, an
adhesive agent can be applied to the tip surfaces of the
reinforcing ribs for use as a securing surface. Therefore, the area
of the securing surface can be ensured. Furthermore, if the ribs
extend in the radial direction, the securing surface can be
extended to the inner peripheral side to ensure the securing
strength.
In at least an embodiment of the present invention, it is desirable
that a first adhesive agent reservoir portion which recesses on the
first side is provided between the ribs adjacent to each other. In
this manner, the adhesive agent that protrudes from the cover
member side securing surface can be retained in the first adhesive
agent reservoir portion. Furthermore, if an adhesive agent is
applied to the tip surfaces of the ribs and used as a securing
surface, the adhesive agent that protrudes from the tip surfaces of
the ribs can be retained in the first adhesive agent reservoir
portion. Therefore, even if the application amount of the adhesive
agent is not strictly controlled, adverse effects that arise due to
protrusion of the adhesive agent caused by excessive application
can be suppressed.
In at least an embodiment of the present invention, the first
adhesive agent reservoir portion doubles as a hollow shape of the
cover member. In this manner, the molding properties of the cover
member can be improved.
In at least an embodiment of the present invention, it is desirable
that the cover member side securing surface is provided with a
chamfered surface formed on an edge which is adjacent to the first
adhesive agent reservoir portion. If such a chamfered shape is
provided, the surface tension of the adhesive agent can to be used
to collect the adhesive agent at the edge of the cover member side
securing surface, and therefore, the securing strength can be
increased. Furthermore, if the ribs include a chamfered surface
formed on an edge of the tip surface facing the second side,
because the surface tension of the adhesive agent can be used to
collect the adhesive agent along the edges of the ribs, the
securing strength can be increased. Further, as a result of
collecting the adhesive agent at the edges of the ribs, which
extend in the radial direction, the detent effect of the cover
member can be increased.
In at least an embodiment of the present invention, the cover
member side securing surface and the resin sealing member side
securing surface are provided on the entire circumference. In this
manner, because the adhesive agent can be distributed to the entire
circumference, the adhesive agent is capable of preventing the
entry of water and the like toward the rotor side, providing a
waterproof effect. Therefore, a waterproof member such as an O-ring
can be omitted, and costs can be reduced.
In at least an embodiment of the present invention, a configuration
can be employed wherein the cover member includes a protrusion
portion that protrudes on the second side and covers an outer
peripheral side of the resin sealing member, an engagement
protrusion portion is provided on an outer peripheral surface of
the resin sealing member, and the protrusion portion includes a
rotation engagement portion that engages the engagement protrusion
portion as a result of the cover member being rotated around the
rotating shaft in a state where the cover member is in contact with
the resin sealing member in the rotation axis line direction. In
this manner, because the cover member is relatively rotated with
respect to the resin sealing member at the time the rotation
engagement portion is engaged, the adhesive agent can be spread in
the circumferential direction. Furthermore, for example, if the
adhesive agent is delivered to the entire circumference to provide
a waterproof effect, and an O-ring is omitted, malfunctions such as
the twisting of the O-ring caused by rotation of the cover member
can be resolved.
In at least an embodiment of the present invention, it is desirable
that the ribs and the gate marks are each disposed at equal angular
intervals. In this manner, the cover member can be uniformly
reinforced.
Next, a pump device of at least an embodiment of the present
invention includes: the motor described above; and an impeller
attached to an end portion of the rotating shaft which passes
through the cover member and protrudes on the first side of the
cover member.
According to at least an embodiment of the present invention, the
cover member secured to the resin sealing portion is a resin molded
article, and ribs are formed on the cover member at positions that
overlap with each adjacent gate mark. Therefore, locations (weld
lines) at which resin flowing in from adjacent gates merge at the
time of molding the cover member can be strengthened by the ribs.
As a result, the strength of the cover member can be ensured.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments will now be described, by way of example only, with
reference to the accompanying drawings which are meant to be
exemplary, not limiting, and wherein like elements are numbered
alike in several Figures, in which:
FIG. 1 is an external perspective view of a pump device to which at
least an embodiment of the present invention has been applied.
FIG. 2A and FIG. 2B are a cross-sectional view of the pump device
and a partially enlarged view thereof.
FIG. 3 is an exploded perspective view of a motor viewed from the
output side.
FIG. 4 is an exploded perspective view of the motor viewed from the
counter output side.
FIG. 5 is a perspective view of a stator viewed from the counter
output side.
FIG. 6 is a perspective view of the stator viewed from the output
side.
FIG. 7 is an exploded cross-sectional view of the motor.
FIG. 8 is a plan view of a cover member viewed from the counter
output side.
FIG. 9A and FIG. 9B are an enlarged cross-sectional view of an
adhesive securing portion between a resin sealing member side
securing surface and the cover member.
DETAILED DESCRIPTION
Hereinafter, an embodiment of a pump device and a motor to which at
least an embodiment of the present invention has been applied is
described with reference to the drawings.
Overall Configuration of Pump Device
FIG. 1 is an external perspective view of a pump device 1 to which
at least an embodiment of the present invention has been applied.
Furthermore, FIG. 2A is a cross-sectional view of the pump device
1, and FIG. 2B is a partially enlarged view of region A in FIG. 2A.
The pump device 1 includes: a motor 2; a case body 3 attached to
the motor 2 that forms a pump chamber 4 between the motor 2 and the
case body 3; and an impeller 6 which is attached to a rotating
shaft 5 of the motor 2 and disposed inside the pump chamber 4. The
case body 3 is provided with a fluid inlet port 7 and discharge
port 8. When the motor 2 is driven to rotate the impeller 6, fluid
such as water drawn from the inlet port 7 is discharged from the
discharge port 8 via the pump chamber 4.
In the present specification, reference numeral L indicates the
axis line direction of the motor 2, where the output side L1
represents a first side in the axis line L direction, and the
counter output side L2 represents a second side in the axis line L
direction. FIG. 1 is an external perspective view of the pump
device 1 as viewed from the counter output side L2. The rotating
shaft 5 of the motor 2 extends in the axis line L direction.
Furthermore, the side on which the impeller 6 is disposed with
respect to the motor 2 is referred to as the output side L1, and
the opposite side to the output side L1 is referred to as the
counter output side L2. Furthermore, the direction orthogonal to
the axis line L is referred to as the radial direction, and the
axis line L periphery is referred to as the circumferential
direction. As shown in FIG. 2A and FIG. 2B, the inlet port 7 is
provided in a position overlapping the axis line L of the rotating
shaft 5 of the motor 2 inside the case body 3, and the discharge
port 8 is provided outside the rotating shaft 5 in the radial
direction.
FIG. 3 is an exploded perspective view of the motor 2 viewed from
the output side L1, and FIG. 4 is an exploded perspective view of
the motor viewed from the counter output side L2. FIG. 3 and FIG. 4
show a state in which a cover member 14 that constitutes a housing
12 of the motor 2 has been detached from a resin sealing member 13.
The motor 2 is a DC brushless motor, and includes a rotor 10, a
stator 11, and a housing 12 that houses these components. The
housing 12 includes the resin sealing member 13 that covers the
stator 11 from the counter output side L2, and the cover member 14
that covers the resin sealing member 13 from the output side L1.
The cover member 14 is secured to the resin sealing member 13.
The case body 3 is placed on the cover member 14 from the output
side L1. As a result, the space partitioned between the cover
member 14 and the case body 3 forms the pump chamber 4. The resin
sealing member 13 retains a first bearing member 15 that rotatably
supports the counter output side L2 end portion of the rotating
shaft 5 of the rotor 10. The cover member 14 retains a second
bearing member 16 that rotatably supports the middle of the
rotating shaft 5. The output side L1 end portion of the rotating
shaft 5 protrudes from the housing 12 of the motor 2 toward the
inside of the pump chamber 4, and the impeller 6 is attached
thereto.
Rotor
As shown in FIG. 2A and FIG. 2B, the rotor 10 includes a rotating
shaft 5, a magnet 20 surrounding the rotating shaft 5, and a
retaining member 21 that retains the rotating shaft 5 and the
magnet 20. The magnet 20 has an annular shape and is coaxially
disposed with respect to the rotating shaft 5. The outer peripheral
surface of the magnet 20 has N poles and S poles alternatingly
magnetized in the circumferential direction. The rotating shaft 5
is made of stainless steel. The rotating shaft 5 has an annular
groove formed near the center in the axis line L direction, and an
E-ring 24 is secured to the annular groove. The E-ring 24 is a
plate-shaped member made of metal. The E-ring 24 is embedded in the
output side L1 end surface of the retaining member 21.
The rotor 10 includes a first bearing plate 45 disposed on the
counter output side L2 of the retaining member 21, and a second
bearing plate 46 disposed on the output side L1 of the retaining
member 21. The first bearing plate 45 and the second bearing plate
46 are substantially annular metal plates. For example, the first
bearing plate 45 and the second bearing plate 46 are metal washers.
The first bearing plate 45 covers the counter output side L2 end
surface of the retaining member 21 in a state where the rotating
shaft 5 is passing through the center hole. Furthermore, the second
bearing plate 46 covers the output side L1 end surface of the
retaining member 21 and the E-ring 24 in a state where the rotating
shaft 5 is passing through the center hole. The second bearing
plate 46 makes surface contact with the E-ring 24. The first
bearing plate 45 and the second bearing plate 46 are respectively
retained by the counter output side L2 end surface and the output
side L1 end surface of the retaining member 21. The sliding heat
generated as a result of the second bearing plate 46 and the second
bearing member 16 sliding during rotation of the rotor 10 is
transmitted to the rotating shaft 5 via the E-ring 24, and then
dissipated.
Stator
FIG. 5 and FIG. 6 are perspective views of the stator 11, where
FIG. 5 is a perspective view viewed from the counter output side
L2, and FIG. 6 is a perspective view viewed from the output side
L1. The stator 11 includes an annular stator core 51 positioned on
the outer peripheral side of the rotor 10, a plurality of coils 53
wound around the stator core 51 via insulators 52, and a connector
54 for connecting a power supply line that supplies power to the
coils 53.
The stator core 51 is a laminated core formed by laminating thin
magnetic plates made of a magnetic material. As shown in FIG. 5 and
FIG. 6, the stator core 51 includes an annular portion 56 and a
plurality of salient pole portions 57 that protrude radially inward
from the annular portion 56. The plurality of salient pole portions
57 are formed with an equal angular pitch, and are disposed with a
constant pitch in the circumferential direction. The inner
peripheral side end surfaces 57a of the salient pole portions 57
are arc-shaped surfaces with the axis line L as the center. The
inner peripheral side end surfaces 57a of the salient pole portions
57 face the outer peripheral surface of the magnet 20 of the rotor
10 with a slight gap.
The insulators 52 are formed from an insulating material such as a
resin. The insulators 52 have a flanged cylindrical shape and are
provided with a flange portion at both ends in the radial
direction. The insulators 52 are attached to each of the plurality
of salient pole portions 57. The coils 53 are wound around each of
the plurality of salient pole portions 57 via the insulators 52.
The insulators 52 partially cover the counter output side end
surface 56a (see FIG. 6) of the annular portion 56 of the stator
core 51, but the outer peripheral edge section of the counter
output side end surface 56a is not covered by the insulators 52.
Similarly, the insulators 52 partially cover the output side end
surface 56b (see FIG. 5) of the annular portion 56 of the stator
core 51, but the outer peripheral edge section of the output side
end surface 56b is not covered by the insulators 52.
The coils 53 are constituted by a conductive wire 55 made of an
aluminum alloy or a copper alloy. In the present embodiment, a
conductive wire 55 in which an aluminum alloy is covered with a
copper alloy is used. Furthermore, in the present embodiment, the
number of salient pole portions 57 and coils 53 is nine. The motor
2 is a three-phase brushless motor, in which three of the nine
coils 53 are U-phase coils, three of the remaining six coils are
V-phase coils, and the remaining three coils are W-phase coils. The
U-phase coils, V-phase coils, and W-phase coils are arranged in
this order in the circumferential direction. The three U-phase
coils are formed by sequentially winding a single conductive wire
55 around three salient pole portions 57, the three V-phase coils
are formed by sequentially winding a single conductive wire 55
around three salient pole portions 57, and the three W-phase coils
are formed by sequentially winding a single conductive wire 55
around three salient pole portions 57. The conductive wires 55 that
constitute the U-phase coils, the V-phase coils, and the W-phase
coils are routed to the connector 54.
Connector
The connector 54 is shaped so that a male external connector can be
attached and detached. The connector 54 is connected to one of the
plurality of insulators 52. The connector 54 includes a
substantially rectangular connector housing 30, a connection
portion 31 that connects the connector housing 30 and the insulator
52, and terminal pins 40 retained by the connector housing 30. The
connector housing 30 is disposed on the outer peripheral side of
the insulator 52 and on the counter output side L2 of the stator
core 51, and is connected via the connection portion 31 to a
section of the insulator 52 (flange portion 52a) positioned on the
outer peripheral side of the coil 53. The connector housing 30 and
the connection portion 31 are integrally formed with the insulator
52.
The connector 54 is a female connector 54 that includes three
terminal pins 40, namely a terminal pin 40 to which one end portion
of the conductive wire 55 constituting the U-phase coils is
connected, a terminal pin 40 to which one end portion of the
conductive wire 55 constituting the V-phase coils is connected, and
a terminal pin 40 to which one end of the conductive wire 55
constituting the W-phase coils is connected. The other end of the
conductive wire 55 constituting the U-phase coils, the other end of
the conductive wire 55 constituting the V-phase coils, and the
other end of the conductive wire 55 constituting the W-phase coils
are connected to each other to form a common wire.
The connector housing 30 has a substantially rectangular shape with
an opening on the counter output side L2. That is to say, the
connector housing 30 is formed with a connection opening 30a which
is an opening on the counter output side L2. The connector housing
30 includes a cylindrical portion 33 having a rectangular
cylindrical shape that extends in the axis line L direction, and a
bottom portion 32 that closes the output side L1 end portion of the
cylindrical portion 33. The connection opening 30a is provided on
the counter output side L2 end portion of the cylindrical portion
33. As shown in FIG. 6, the cylindrical portion 33 includes an
inner side wall 33a positioned on the central side (that is to say,
the insulator 52 side) of the stator 11, an outer side wall 33b
parallel to the inner side wall 33a, and side walls 33c and 33d
connected to the inner side wall 33a and the outer side wall 33b.
The internal space of the connector housing 30 is divided into
three portions by partition walls 33e and 33f parallel to the side
walls 33c and 33d. Inside each of the spaces partitioned by the
partition walls 33e and 33f is disposed one terminal connection
portion 41 (see FIG. 2A) corresponding to an end portion of one of
the terminal pins 40. When a male external connector is attached to
the connection opening 30a, the terminals provided on the external
connector make contact with the terminal pins 40.
As shown in FIG. 5, the bottom portion 32 is formed having the same
number of through holes 34 as terminal pins 40. Three terminal pins
40 are attached to the connector housing 30 of the present
embodiment, and therefore, through holes 34 are formed in three
locations. The three through holes 34 are arranged in a line in the
direction orthogonal to the radial direction of the stator 11. As
shown in FIG. 2A and FIG. 5, a concave portion 35 positioned
radially inward with respect to the through holes 34 (that is to
say, on the insulator 52 side) is formed in the output side L1
surface of the bottom portion 32. The concave portion 35 has a
hollow shape that recesses on the counter output side L2, and
extends in a groove shape along the direction in which the three
through holes 34 are disposed. Furthermore, the same number of
through holes 36 as through holes 34 (see FIG. 2A) is provided in
the output side L1 surface of the connection portion 31. That is to
say, three pairs of through holes 34 and through holes 36 are
provided in the output side L1 surface of the connector 54.
Retaining grooves 37 that intersect the concave portion 35 (see
FIG. 5) are respectively provided between the three pairs of
through holes 34 and through holes 36. Sections of the terminal
pins 40 that extend from the through holes 34 to the through holes
36 (which are joining portions 43 as described below) are retained
by the retaining grooves 37.
The terminal pins 40 are formed by bending a metal wire having a
square cross-sectional shape. The terminal pins 40 may also be
formed by bending a metal wire having a circular cross-sectional
shape. As shown in FIG. 2A, the terminal pin 40 is constituted by a
terminal connection portion 41 which is press-fitted into the
connector housing 30 and protrudes toward the connection opening
30a, a conductive wire connection portion 42 disposed between the
connector housing 30 and the insulator 52, and a joining portion 43
which connects the terminal connection portion 41 and the
conductive wire connection portion 42. The terminal connection
portion 41 and the conductive wire connection portion 42 extend in
a direction parallel with the axis line L direction. Furthermore,
the joining portion 43 extends in a direction orthogonal to the
axis line L direction, and is connected to the terminal connection
portion 41 and the conductive wire connection portion 42
substantially at right angles.
The terminal pin 40 is attached to the connector housing 30 by
press-fitting the terminal connection portion 41 with respect to
the through hole 34 in the axis line L direction, and passing the
conductive wire connection portion 42 through the through hole 36.
As described above, by retaining the joining portion 43 in the
retaining groove 37 formed in the outside surface of the connector
housing 30, rotation of the terminal pin 40 is prevented. The tip
of the conductive wire connection portion 42 is provided with a
detachment prevention portion 42a formed by bending the tip portion
of the conductive wire connection portion 42 radially inward in a
substantially perpendicular fashion after being assembled to the
connector housing 30. That is to say, the conductive wire
connection portion 42 is constituted by a rising portion 42b that
extends along the inner side wall 33a, and the detachment
prevention portion 42a. The bending angle of the detachment
prevention portion 42a may be an obtuse angle rather than being
substantially perpendicular.
As shown in FIG. 6, the three conductive wire connection portions
42 are disposed at constant intervals in a direction orthogonal to
the radial direction along the inner side wall 33a of the connector
housing 30. The connector housing 30 includes wall portions 38
which orthogonally protrude radially inward from the inner side
wall 33a. The wall portions 38 are provided at two locations
representing the midpoint positions between adjacent conductive
wire connection portions 42. The radially inward end edges of the
wall portions 38 are positioned further radially inward than the
rising portions 42b. On the other hand, in the wall portions 38,
the axis line L direction end edges are positioned further on the
output side L1 than the detachment prevention portions 42a. That is
to say, the wall portions 38 have a shape whose width reaches
adjacent rising portions 42b, but whose height does not reach
adjacent detachment prevention portions 42a.
As shown in FIG. 6, the insulator 52 positioned on the inner
peripheral side of the connector 54 includes a flange portion 52a
provided on the outer peripheral side of the coil 53. The insulator
52, which is integrally formed with the connector 54, includes four
cylindrical guide convex portions 39 that protrude from the counter
output side L2 surface of the flange portion 52a which covers the
outer peripheral surface of the stator core 51. The four guide
convex portions 39 are arranged at a constant pitch in the
circumferential direction. One conductive wire 55 is connected to
each of the three conductive wire connection portions 42. The three
conductive wires 55, which constitute the U-phase coils, the
V-phase coils, and the W-phase coils, are guided by the four guide
convex portions 39 and are routed from the coils 53 to the
conductive wire connection portions 42. That is to say, the four
guide convex portions 39 guide one of the three conductive wires 55
from the coils 53 positioned on the inner peripheral side of the
connector housing 30 to the middle of the three conductive wire
connection portions 42, guide one of the two remaining conductive
wires 55 from the coils 53 positioned on the first side in the
circumferential direction of the coils 53 positioned on the inner
peripheral side of the connector housing 30 to the conductive wire
connection portion 42 positioned on the first side end in the
circumferential direction, and guide the last conductive wire 55
from the coil 53 positioned on the second side in the
circumferential direction of the coils 53 positioned on the inner
peripheral side of the connector housing 30 to the conductive wire
connection portion 42 positioned on the second side end in the
circumferential direction.
The conductive wires 55 are guided by the guide convex portions 39
and routed toward the conductive wire connection portions 42, and
then routed along the rising portions 42b to the detachment
prevention portions 42a. Because the conductive wires 55 are routed
along the rising portions 42b, short circuiting is prevented by
means of the wall portions 38. The conductive wires 55 are wound
around the rising portions 42b or the detachment prevention
portions 42a, and are soldered to the rising portions 42b or the
detachment prevention portions 42a. As described above, because the
wall portions 38 have a height that does not reach the detachment
prevention portions 42a, a soldering iron is capable of soldering
by closely approaching the upper ends of the detachment prevention
portions 42a and the rising portions 42b without being blocked by
the wall portions 38.
Resin Sealing Member
FIG. 7 is an exploded cross-sectional view of the motor 2, and is a
cross-sectional view of a state in which the cover member 14 has
been separated from the resin sealing member 13. As shown in FIG.
2A and FIG. 2B to FIG. 4, and FIG. 7, the resin sealing member 13
includes a coil 53, an insulator 52, and a substantially
disk-shaped sealing member bottom portion 65 covering the stator
core 51 from the counter output side L2. Furthermore, the resin
sealing member 13 includes a connector sealing portion 66, which
extends from the sealing member bottom portion 65 toward the outer
peripheral side and covers the connector 54, and a sealing member
cylindrical portion 67, which extends from the sealing member
bottom portion 65 toward the output side L1 and covers the coil 53,
the insulator 52, and the stator core 51. The sealing member
cylindrical portion 67 has a thick cylindrical shape. The central
axis line of the sealing member cylindrical portion 67 coincides
with the axis line L of the motor 2.
A bearing member retaining concave portion 68 is provided in a
central section of the sealing member bottom portion 65. The
bearing member retaining concave portion 68 retains a first bearing
member 15 that rotatably supports the counter output side L2 end
portion of the rotating shaft 5 of the rotor 10. The first bearing
member 15 is made of resin, and has a shape which includes a
cylindrical support portion provided with a through hole in which
the rotating shaft 5 is disposed, and a flange portion that expands
from the output side L1 end portion of the cylindrical portion
toward the outer peripheral side. The contour shape of the first
bearing member 15 when viewed from the axis line L direction is a
letter-D shape. The first bearing member 15 is secured to the
bearing member retaining concave portion 68 in a state where the
flange portion is making contact with the sealing member bottom
portion 65 from the output side L1. In the first bearing member 15,
the support portion through which the rotating shaft 5 is inserted
functions as a radial bearing of the rotating shaft 5, and the
flange portion functions as a thrust bearing of the rotor 10. That
is to say, the first bearing plate 45 secured to the retaining
member 21 of the rotor 10 slides on the flange portion of the first
bearing member 15.
As shown in FIG. 2A and FIG. 2B, the sealing member bottom portion
65 includes a cylindrical bearing support section 65a that
surrounds the first bearing member 15 from the outer peripheral
side in the radial direction, a circular closed section 65b that
closes the lower end opening of the bearing support section 65a, a
coil sealing section 65c positioned below the coil 53, and a
connection section 65d that connects between the bearing support
section 65a and the coil sealing section 65c. The bearing support
section 65a and the closed section 65b constitute the bearing
member retaining concave portion 68. The counter output side L2
surface of the coil sealing section 65c includes, along the shape
of each coil 53 would around the insulator 52, a tapered surface
65e increasingly inclined to the counter output side L2 toward the
outer peripheral side, and an annular surface 65f which is provided
on the outer peripheral side of the tapered surface 65e and is
perpendicular to the axis line L direction.
As shown in FIG. 2A, FIG. 4, and FIG. 5, the connector sealing
portion 66 has a substantially rectangular shape as a whole. The
connector sealing portion 66 includes a connector sealing portion
bottom portion 66a covering the output side L1 of the connector 54,
a connector sealing portion outer peripheral portion 66b covering
both the outer radial side and the circumferential direction of the
connector 54, and a connector sealing portion inner peripheral
portion 66c which is positioned on the inner peripheral side of the
connector housing 30 and covers the counter output side L2 of the
connection portion 31, and protrudes from the sealing member bottom
portion 65 to the counter output side L2. The connector sealing
portion bottom portion 66a and the connector sealing portion outer
peripheral portion 66b protrude from the sealing member cylindrical
portion 67 on the outer peripheral side. Furthermore, the connector
sealing portion inner peripheral portion 66c has a shape which is
raised by one step from the annular surface 65f of the sealing
member bottom portion 65. That is to say, the counter output side
L2 end surface 66d of the connector sealing portion inner
peripheral portion 66c is in a position that protrudes further on
the counter output side L2 by one step relative to the annular
surface 65f of the sealing member bottom portion 65.
In the connector 54, the open end portion of the connector housing
30 having the connection opening 30a, to which a male connector is
attached and detached, protrudes from the connector sealing portion
66 on the counter output side L2 and is exposed to the outside. The
connection opening 30a is provided in a position protruding by a
dimension H (see FIG. 4) from the counter output side L2 end
surface 66d of the connector sealing portion 66. In the connector
54, only the open end portion of the connector housing 30 having
the connection opening 30a is exposed to the outside, and the
joining portion 43 and the conductive wire connection portion 42 of
the terminal pin 40 are completely covered by the connector sealing
portion 66. Therefore, the connector sealing portion 66 prevents
the terminal pin 40 from falling loose, and protects the terminal
pin 40 from fluid. Furthermore, the conductive wire 55 routed from
the coil 53 to the connector 54 is also covered by the connector
sealing portion 66, and is protected from fluid.
As shown in FIG. 2A, FIG. 2B and FIG. 3, the sealing member
cylindrical portion 67 includes a large diameter cylindrical
section 81 which connects to the sealing member bottom portion 65,
and a small diameter cylindrical section 82 having a smaller
outside diameter dimension than the large diameter cylindrical
section 81. The small diameter cylindrical section 82 includes a
first small diameter cylindrical section 82a which constitutes the
output side L1 end portion of the sealing member cylindrical
portion 67, and a second small diameter cylindrical section 82b
provided between the first small diameter cylindrical section 82a
and the large diameter cylindrical section 81. The first small
diameter cylindrical section 82a has a slightly smaller outside
diameter than the second small diameter cylindrical section
82b.
On the outer peripheral surface of the sealing member cylindrical
portion 67 is formed a resin sealing member side position
regulating surface 70, which is a stepped surface facing the output
side L1 at the boundary section between the second small diameter
cylindrical section 82b and the large diameter cylindrical section
81. The resin sealing member side position regulating surface 70 is
orthogonal to the axis line L direction. As described below, the
resin sealing member side position regulating surface 70 is a
surface that makes contact with the cover member 14 in the axis
line L direction. Furthermore, the sealing member cylindrical
portion 67 includes on the output side L1 end portion a resin
sealing member side securing surface 71, which is an annular end
surface orthogonal to the axis line L direction. As described
below, the resin sealing member side securing surface 71 opposes
the cover member 14 with a predetermined gap. The cover member 14
is secured to the resin sealing member 13 by an adhesive agent
disposed in the gap between the resin sealing member side securing
surface 71 and the cover member 14.
The outside diameter of the large diameter cylindrical section 81
is larger than the outside diameter of the annular portion 56 of
the stator core 51, and the outside diameter of the second small
diameter cylindrical section 82b is smaller than the outside
diameter of the annular portion 56 of the stator core 51.
Furthermore, the resin sealing member side position regulating
surface 70 is positioned on the same plane as the counter output
side end surface 56a of the annular portion 56 of the stator core
51. As a result, a plurality of arc-shaped opening portions 83 (see
FIG. 3), which expose an outer peripheral edge section of the
counter output side end surface 56a of the annular portion 56 of
the stator core 51 on the output side L1, is formed on an inner
peripheral section of the resin sealing member side position
regulating surface 70.
As shown in FIG. 2A, FIG. 2B and FIG. 3, the inner peripheral
surface of the sealing member cylindrical portion 67 is provided
with, from the counter output side L2 toward the output side L1, a
small diameter inner peripheral surface section 67a, and a large
diameter inner peripheral surface section 67b having a larger
inside diameter dimension than the small diameter inner peripheral
surface section 67a. As shown in FIG. 2A and FIG. 2B, the small
diameter inner peripheral surface section 67a is provided with a
plurality of opening portions which expose the inner peripheral
side end surfaces 57a of the salient pole portions 57 of the stator
core 51 to the inner peripheral side. Furthermore, as shown in FIG.
3, the small diameter inner peripheral surface section 67a is
provided with a plurality of groove-shaped notched portions 69 that
extend in the axis line L direction. Each of the plurality of
notched portions 69 is centrally positioned in the circumferential
direction of each salient pole portion 57 of the stator core 51,
and extend from the output side end surface 57b of the salient pole
portion 57 (see FIG. 5) to the output side L1 end surface of the
small diameter inner peripheral surface section 67a. Consequently,
the output side end surfaces 57b of the salient pole portions 57 of
the stator core 51 are exposed on the output side L1 at the angular
positions in which the notched portions 69 are provided.
The outer peripheral surface of the large diameter cylindrical
section 81 is provided with four engagement protrusion portions 85
which protrude on the outer peripheral side at equal angular
intervals. The engagement protrusion portions 85 engage rotation
engagement portions 86 provided on the cover member 14 as described
below. The engagement protrusion portions 85 engage the rotation
engagement portions 86 to regulate the detachment of the cover
member 14 from the resin sealing member 13.
The resin sealing member 13 completely covers the coil 53, and
protects the coil 53 from fluid. Furthermore, except for the
opening (connection opening 30a) to which a male connector is
attached and detached, the resin sealing member 13 is integrally
formed up to the connector sealing portion 66 covering the
connector 54, and prevents the terminal pin 40 assembled to the
connector 54 from falling loose while also protecting the
connection portion between the terminal pin 40 and the conductive
wire 55 from fluid. The resin sealing member 13 is formed from a
BMC (Bulk Molding Compound). In the present embodiment, the resin
sealing member 13 is formed by placing the stator 11 in a mold, and
injecting and curing a resin material inside the mold. That is to
say, the resin sealing member 13 is integrally molded with the
stator 11 by means of insert molding.
When insert molding is performed, the resin sealing member 13 is
molded by injecting a resin into a mold in a state where which the
stator core 51 is placed inside the mold and positioned in the
radial direction and in the axis line L direction by bringing the
stator core 51 into contact with the mold. Consequently, the
accuracy with which the stator core 51 and the resin sealing member
13 are relatively positioned is improved. For example, a
cylinder-shaped mold section is provided in advance in the mold,
and the outer peripheral surface of the mold section is brought
into contact with the inner peripheral side end surfaces 57a of the
salient pole portions 57 to position the stator core 51 in the
radial direction. As a result, as described above, the inner
peripheral side end surfaces 57a of the salient pole portions 57 of
the stator core 51 are exposed from the resin sealing member 13.
Furthermore, when insert molding is performed, the mold is provided
in advance with a first contact section capable of making contact
with the output side end surfaces 57b of the salient pole portions
57, and a second contact section capable of making contact with the
output side end surface 56b of the annular portion 56, the stator
core 51 is positioned in the axis line L direction by bringing the
first contact section and the second contact section into contact
with the stator core 51. Consequently, as described above, a
section of the output side end surface 57b of each salient pole
portions 57 of the stator core 51 is exposed on the output side L1.
Moreover, an outer peripheral section of the output side end
surface 56b of the annular portion 56 is exposed on the output side
L1.
As shown in FIG. 4, a plurality of holes 17 are formed in the
sealing member bottom portion 65 which are continuous from the
counter output side L2 surface of the sealing member bottom portion
65 to the counter output side L2 end surface of the insulator 52.
In the present embodiment, six holes 17 are formed in the sealing
member bottom portion 65. Specifically, a set of two holes 17
arranged with a 40.degree. pitch around the axis line L are formed
in three locations with a 120.degree. pitch. The holes 17 have a
shape that support pressing pins for the stator 11 set inside the
mold to be pressed in the axis line L direction against a support
surface (the first contact section and the second contact section
described above) inside the mold at the time of molding.
Cover Member
FIG. 7 is an exploded cross-sectional view of the motor, and shows
a state in which the cover member 14 has been detached from the
resin sealing member 13. The cover member 14 is made of resin, and
is secured on the output side L1 of the resin sealing member 13.
The cover member 14 includes a disk-shaped cover member ceiling
portion 91, and a cover member cylindrical portion 92 that
protrudes from the cover member ceiling portion 91 on the counter
output side L2. The center of the cover member ceiling portion 91
is provided with a through hole 93 which passes through in the axis
line L direction. A circular concave portion 94 surrounding the
through hole 93 is provided at the center of the output side L1
surface of the cover member ceiling portion 91, and an annular seal
member 95 is disposed on the circular concave portion 94. The seal
member 95 is disposed in the gap between the rotating shaft 5 and
the cover member 14.
As shown in FIG. 4 and FIG. 7, the central section of the counter
output side L2 surface of the cover member ceiling portion 91 is
provided with a bearing member retaining cylindrical portion 97
positioned coaxially with respect to the through hole 93. As shown
in FIG. 2A and FIG. 2B and FIG. 7, the second bearing member 16 is
retained in the center hole of the bearing member retaining
cylindrical portion 97. The second bearing member 16 is an
identical member to the first bearing member 15 described above,
which is disposed in the opposite axis line L direction. That is to
say, the second bearing member 16 is made of resin, and includes a
cylindrical support portion provided with a through hole in which
the rotating shaft 5 is disposed, and a flange portion that expands
from the output side L1 end portion of the cylindrical portion
toward the outer peripheral side. The second bearing member 16 is
secured to the bearing member retaining cylindrical portion 97 in a
state where the flange portion is making contact with the bearing
member retaining cylindrical portion 97 from the counter output
side L2. In the second bearing member 16, the support portion
through which the rotating shaft 5 is inserted functions as a
radial bearing of the rotating shaft 5, and the flange portion
functions as a thrust bearing of the rotor 10. That is to say, the
second bearing plate 46 secured to the retaining member 21 of the
rotor 10 slides on the flange portion of the second bearing member
16.
FIG. 8 is a plan view of the cover member 14 viewed from the
counter output side L2. As shown in FIG. 4, FIG. 7 and FIG. 8, an
annular cover member side securing surface 72 that connects to the
inner peripheral surface of the cover member cylindrical portion 92
is provided along the outer peripheral edge of the counter output
side L2 surface of the cover member ceiling portion 91. Further, a
circular inner annular rib 99 is provided between the bearing
member retaining cylindrical portion 97 and the cover member side
securing surface 72 on the counter output side L2 surface of the
cover member ceiling portion 91. The bearing member retaining
cylindrical portion 97, the cover member side securing surface 72,
and the inner annular rib 99 are coaxially provided. Moreover, a
plurality of radial ribs 98 and a plurality of first adhesive agent
reservoir portions 100 are provided between the inner annular rib
99 and the cover member side securing surface 72. In addition, a
plurality of radial ribs 96 is provided between the inner annular
rib 99 and the bearing member retaining cylindrical portion 97.
The inner annular rib 99 and the radial ribs 98 and 96 are convex
portions that protrude on the counter output side L2. Furthermore,
the first adhesive agent reservoir portions 100 are concave
portions which recess further on the output side L1 than the cover
member side securing surface 72 and the tip surfaces 98a of the
radial ribs 98. The first adhesive agent reservoir portions 100 are
concave portions that utilize the hollow shape of the cover member
14. That is to say, the first adhesive agent reservoir portions 100
double as the hollow shape of the cover member 14. Moreover,
concave portions serving as a hollow shape are also formed on the
inner peripheral side of the inner annular rib 99 between the
radial ribs 96.
In the present embodiment, eight radial ribs 98 are radially
disposed at an angular interval of 45 degrees. Furthermore, the
radial ribs 96 are disposed at the same angular positions as the
radial ribs 98. The first adhesive agent reservoir portions 100 are
substantially fan-shaped concave portions provided between two
radial ribs 98 that are adjacent in the circumferential direction,
and are provided in eight locations in the present embodiment. The
first adhesive agent reservoir portions 100 are partitioned on both
circumferential direction sides by the radial ribs 98, and are
partitioned on the inner peripheral side by the inner annular rib
99. Moreover, the first adhesive agent reservoir portions 100 are
disposed on the inner peripheral side of the cover member side
securing surface 72.
The amount of protrusion of the bearing member retaining
cylindrical portion 97 toward the counter output side L2 is greater
than the amount of protrusion of the inner annular rib 99.
Furthermore, the inner annular rib 99 and the radial ribs 96
protrude further on the counter output side L2 than the cover
member side securing surface 72. On the other hand, the tip
surfaces 98a of the radial ribs 98 are positioned on the same plane
as the cover member side securing surface 72. The tip surface of
the bearing member retaining cylindrical portion 97, the tip
surface of the inner annular rib 99, the tip surfaces of the radial
ribs 98 and 96, and the cover member side securing surface 72 are
all planes which are perpendicular to the axis line L. Chamfered
surfaces are provided on the edges the first adhesive agent
reservoir portions 100 on the outer peripheral side and in both
circumferential directions. That is to say, a chamfered surface 72a
is provided on the inner peripheral side edge of the cover member
side securing surface 72. Furthermore, chamfered surfaces 98b are
provided at the corner portions where the tip surfaces 98a and side
surfaces of the radial ribs 98 are connected. Chamfered surfaces
are also provided on the edges of the radial ribs 96 and the inner
annular rib 99.
As shown in FIG. 4 and FIG. 7, the inside diameter of the cover
member cylindrical portion 92 increases stepwise from the output
side L1 toward the counter output side L2. That is to say, the
inner peripheral surface of the cover member cylindrical portion 92
includes, in order from the output side L1, a first small diameter
inner peripheral surface 92a, a second small diameter inner
peripheral surface 92b, and a large diameter inner peripheral
surface 92c. The cover member side position regulating surface 73,
which is an annular step surface facing the counter output side L2,
is formed on the boundary section between the second small diameter
inner peripheral surface 92b and the large diameter inner
peripheral surface 92c. The cover member side position regulating
surface 73 is a plane orthogonal to the axis line L.
The cover member cylindrical portion 92 includes an upper annular
cylindrical section 92d, which overlaps with the small diameter
cylindrical section 82 of the resin sealing member 13 in the axis
line L direction and covers the small diameter cylindrical section
82 of the resin sealing member 13 from the outer peripheral side,
and a lower annular cylindrical section 92e, which is positioned on
the outer peripheral side of the large diameter cylindrical section
81 of the resin sealing member 13. The upper annular cylindrical
section 92d is a section further on the output side L1 than the
cover member side position regulating surface 73. Furthermore, the
lower annular cylindrical section 92e is a protrusion portion that
protrudes further on the counter output side L2 than the cover
member side position regulating surface 73, and covers the outer
peripheral side of the resin sealing member 13.
As shown in FIG. 4, the lower annular cylindrical section 92e of
the cover member cylindrical portion 92 is provided with rotation
engagement portions 86 that engage the engagement protrusion
portions 85 of the resin sealing member 13 in four locations in the
circumferential direction. As shown in FIG. 3 and FIG. 4, the
rotation engagement portions 86 in three of the four locations are
first rotation engagement portions 86A, which include a groove
portion 861 which extends from the counter output side L2 edge of
the cover member cylindrical portion 92 toward the output side L1
and a substantially rectangular notched portion 862 which is
connected to the groove portion 861 and extends in the
circumferential direction. The remaining location is a second
rotation engagement portion 86B, which includes a notched portion
863 which extends from the counter output side L2 edge of the cover
member cylindrical portion 92 toward the output side L1, and a
notched portion 864 connected to the notched portion 863 and which
extends in the circumferential direction. The second rotation
engagement portion 86B has an elastically deformable arm portion
865 provided on the counter output side L2 of the notched portion
864, and the arm portion 865 is provided with a hook portion 866
which is capable of engaging the engagement protrusion portion 85
in the circumferential direction.
Positioning Structure and Securing Structure of Cover Member
The cover member 14 is covered by the resin sealing member 13 from
the output side L1 in a state where the rotor 10 is disposed on the
inside of the resin sealing member 13, and the rotor 10 is
supported by the first bearing member 15. When the resin sealing
member 13 is covered by the cover member 14, as shown in FIG. 2A
and FIG. 2B, a lower end section of the inner annular rib 99 is
fitted to the inner peripheral side of the sealing member
cylindrical portion 67 of the resin sealing member 13.
Consequently, the cover member 14 and the resin sealing member 13
are positioned in the radial direction, and the axis line L of the
rotating shaft 5 coincides with the central axis line of the stator
11. The cover member 14 is positioned in the axis line L direction
as a result of the cover member side position regulating surface 73
provided on the cover member cylindrical portion 92 making contact
in the axis line L direction with the resin sealing member side
position regulating surface 70, which is a step surface provided on
the outer peripheral surface of the resin sealing member 13.
Consequently, the cover member ceiling portion 91 covers the rotor
10 and the resin sealing member 13 from above in a state where the
rotating shaft 5 is passing through cover member ceiling portion 91
in the vertical direction. Furthermore, a seal member 95 disposed
in a circular concave portion 94 of the cover member ceiling
portion 91 seals together the rotating shaft 5, the cover member
14, and the second bearing member 16. In addition, the cover member
cylindrical portion 92 surrounds an output side L1 section of the
resin sealing member 13 from the outer peripheral side.
Thereafter, the cover member 14 and the resin sealing member 13 are
relatively rotated in the circumferential direction, and as shown
in FIG. 1, the engagement protrusion portions 85 of the resin
sealing member 13 and the rotation engagement portions 86 (the
first rotation engagement portions 86A and the second rotation
engagement portion 86B) of the cover member 14 engage each other.
That is to say, the cover member 14 is rotated in the
circumferential direction with respect to the resin sealing member
13 in a state where the four engagement protrusion portions 85 are
inserted into the groove portions 861 or the notched portions 863
such that the engagement protrusion portions 85 engage the notched
portions 862 and 864. The cover member 14 and the resin sealing
member 13 are positioned in the circumferential direction as a
result of the engagement protrusion portion 85 in one of the four
locations engaging the hook portion 866 provided on the second
rotation engagement portion 86B. When the procedure that relatively
rotates the cover member 14 and the resin sealing member 13 in the
circumferential direction is performed manually, the resin sealing
member 13 can be relatively rotated with respect to the cover
member 14 by supporting the resin sealing member 13 using the
connector sealing portion 66, which projects from the sealing
member cylindrical portion 67 on the outer peripheral side, as a
fulcrum.
FIG. 9 is an enlarged cross-sectional view of the adhesive securing
portion between the resin sealing member side securing surface 71
and the cover member 14, where FIG. 9A is an enlarged
cross-sectional view of the adhesive securing portion between the
resin sealing member side securing surface 71 and the cover member
side securing surface 72 (radial direction partial cross-sectional
view), and FIG. 9B is an enlarged cross-sectional view of the
adhesive securing portion between the resin sealing member side
securing surface 71 and the radial rib 98 (circumferential
direction partial cross-sectional view). When the cover member 14
is covered by the resin sealing member 13, an adhesive agent is
applied to the resin sealing member side securing surface 71 which
is an output side L1 end surface of the sealing member cylindrical
portion 67 (see FIG. 3 and FIG. 7). When the cover member side
position regulating surface 73 and the resin sealing member side
position regulating surface 70 are brought into contact in the axis
line L direction, the resin sealing member side securing surface 71
faces the cover member side securing surface 72 and the tip surface
98a of the radial rib 98 with a predetermined gap.
The adhesive agent applied to the resin sealing member side
securing surface 71 is cured in a state where the gap is filled
between the resin sealing member side securing surface 71 and the
cover member side securing surface 72, and between the resin
sealing member side securing surface 71 and the tip surface 98a of
the radial rib 98. Therefore, as shown in FIG. 9A, the cover member
side securing surface 72 is secured to the resin sealing member
side securing surface 71 via the adhesive layer 110. Further, as
shown in FIG. 9B, the tip surface 98a of the radial rib 98 is
secured to the resin sealing member side securing surface 71 via
the adhesive layer 110. The resin sealing member side securing
surface 71 and the cover member side securing surface 72 are both
annular surfaces, and are provided on the entire circumference of
the cover member 14. Therefore, because the adhesive agent layer
110 is formed on the entire circumference, the waterproof
properties are ensured by the adhesive agent layer 110.
Here, if the cover member 14 and the resin sealing member 13 are
relatively rotated in the circumferential direction before curing
the adhesive so that the engagement protrusion portions 85 and the
rotation engagement portions 86 engage each other, the adhesive
agent applied to the resin sealing member side securing surface 71
can be spread in the circumferential direction. Therefore, the
adhesive agent can be distributed to the locations where adhesion
is desired, and the adhesive agent can be distributed with
certainty over the entire circumference. Furthermore, if the cover
member 14 and the resin sealing member 13 are relatively rotated in
the circumferential direction, the adhesive agent enters between
the chamfered surface 98b provided at a corner portion of the
radial rib 98 and the resin sealing member side securing surface
71. When an adhesive agent with a low viscosity is used, surface
tension causes the adhesive agent to collect in a section with a
wide gap. In other words, the adhesive agent collects along the
edges of the cover member side securing surface 72 and the radial
rib 98, which are provided with the chamfered surfaces 72a and
98b.
The first adhesive agent reservoir portion 100 is provided in a
position adjacent in the inner peripheral side with respect to the
cover member side securing surface 72. Therefore, when excessive
adhesive agent is applied to the resin sealing member side securing
surface 71, the adhesive agent protruding on the inner peripheral
side of the cover member side securing surface 72 is retained by
the first adhesive agent reservoir portion 100. Therefore, entry of
the adhesive agent toward the rotor 10 side is suppressed.
Furthermore, the adhesive agent protruding on both circumferential
direction sides of the radial rib 98 is also retained by the first
adhesive agent reservoir portion 100.
The cover member 14 includes a second adhesive agent reservoir
portion 101 provided between the cover member side securing surface
72 and the cover member side position regulating surface 73. That
is to say, as shown in FIG. 2B, a first small diameter inner
peripheral surface 92a and a second small diameter inner peripheral
surface 92b are provided between the cover member side securing
surface 72 and the cover member side position regulating surface
73, but the second small diameter inner peripheral surface 92b is
disposed so as to leave a predetermined gap in the radial direction
with the outer peripheral surface of the small diameter cylindrical
section 82 of the resin sealing member 13. This gap becomes the
second adhesive agent reservoir portion 101. Therefore, when an
excessive amount of adhesive agent is applied to the resin sealing
member side securing surface 71, the adhesive agent protruding on
the outer peripheral side from the cover member side securing
surface 72 is retained by the second adhesive agent reservoir
portion 101. Therefore, the adhesive agent is prevented from
protruding from the gap between the cover member 14 and the resin
sealing member 13 toward the outer peripheral surface of the motor
2.
Positional Relationship Between Gate Marks and Radial Ribs
The cover member 14 is a resin molded article. As shown in FIG. 3,
a plurality of gate marks 102, which are marks from a resin
injection port into the mold, are formed on the output side L1
surface of the cover member 14. The plurality of gate marks 102 are
annularly disposed at equal angular intervals around the rotating
shaft 5. For example, in the present embodiment, the gate marks 102
are formed in four locations at a 90.degree. pitch around the
rotating shaft 5. On the other hand, the plurality of radial ribs
98 are disposed at equal angular intervals around the rotating
shaft 5 on the counter output side L2 surface of the cover member
14, and the radial ribs 98 are formed in positions corresponding to
the positions of the gate marks 102. That is to say, the angular
positions of the gate marks 102 and the radial ribs 98 are set such
that circumferential direction midpoints P of gate marks 102 that
are adjacent to each other in the circumferential direction
coincide with certainty with the positions in which one of the
plurality of radial ribs 98 is formed.
In the present embodiment, as shown in FIG. 8, the four gate marks
102 are each provided in positions overlapping with four of the
eight radial ribs 98 when viewed in the axis line L direction.
Further, the circumferential direction midpoints P of gate marks
102 that are adjacent to each other in the circumferential
direction are each in positions overlapping with the radial ribs 98
when viewed in the axis line L direction. More specifically, the
angular positions of the gate marks 102 and the radial ribs 98 are
set such that the central positions of the circumferential
direction widths of the radial ribs 98 and the midpoints P overlap
when viewed in the axis line L direction. The circumferential
direction midpoints P of the gate marks 102 coincide with locations
(weld lines P1: imaginary lines indicated by single-dotted chain
line in FIG. 3) at which the resin flowing in from adjacent gates
merge at the time of molding the cover member 14. Therefore, by
matching the angular positions of the midpoints P and the angular
positions of the radial ribs 98, the radial ribs 98 can be formed
on the weld line P1, and the strength of the cover member 14 can be
ensured as a result of the radial ribs 98 reinforcing the sections
overlapping the weld line P1.
Main Effects of Present Embodiment
As described above, in the motor 2 and the pump device 1 of the
present embodiment, a resin molded article is used as the cover
member 14 of the motor 2, the cover member 14 being secured to the
resin sealing member 13 and having radial ribs 98 formed in
positions overlapping each of the midpoints P of adjacent gate
marks 102 in the axis line L direction. Therefore, the radial ribs
98 are capable of reinforcing the locations (weld lines P1) at
which the resin flowing in from adjacent gates merges at the time
of molding the cover member 14. In particular, in the present
embodiment, because the gate marks 102 are annularly disposed
around the rotating shaft 5 and the radial ribs 98 extend in the
radial direction around the rotating shaft 5, the radial ribs 98
can be disposed along the weld lines P1. Therefore, the strength of
the cover member can be ensured. Furthermore, because the radial
ribs 98 and the gate marks 102 are each disposed at equal angular
intervals, the cover member 14 can be uniformly reinforced.
In the present embodiment, the cover member 14 includes the cover
member side securing surface 72 which faces, in the axis line L
direction, the resin sealing member side securing surface 71
provided on the resin sealing member 13, and further, the tip
surfaces 98a of the plurality of radial ribs 98 are positioned on
the same plane as the cover member side securing surface 72.
Therefore, the cover member side securing surface 72 is secured to
the resin sealing member side securing surface 71 via the adhesive
resin layer 110, and further, the tip surfaces 98a of the radial
ribs 98 can be utilized as a securing surface for securing to the
resin sealing member side securing surface 71. Therefore, the area
of the securing surface can be ensured. Furthermore, because the
securing surface can be extended to the inner peripheral side by
means of the radial ribs 98, the securing strength can be
secured.
In the present embodiment, the position regulating surfaces at
which the cover member 14 and the resin sealing member 13 make
contact (the cover member side position regulating surface 73 and
the resin sealing member side position regulating surface 70), and
the securing surfaces at which the cover member 14 and the resin
sealing member 13 are secured by an adhesive agent (the cover
member side securing surface 72 and the resin sealing member side
securing surface 71) are separately provided. Therefore, the cover
member 14 and the resin sealing member 13 can be brought into
contact and positioned with a high accuracy, while being configured
such that the securing surfaces of both members face each other
with a gap in which the adhesive agent is disposed. Therefore, the
accuracy with which the cover member 14 can be positioned in the
axis line L direction with respect to the resin sealing member 13
can be improved. Furthermore, by using an adhesive agent to secure
the resin sealing member 13 and the cover member 14, it is not
necessary to provide a securing structure such as a screw securing
portion or a hook. Therefore, the structure of the securing
location can be simplified.
In the present embodiment, because a first adhesive agent reservoir
portion 100 is provided which recesses further on the output side
L1 (first side in the axis line L direction) than the cover member
side securing surface 72, the adhesive agent that protrudes from
the cover member side securing surface 72 is retained in the first
adhesive agent reservoir portion 100. Therefore, even if the
application amount of the adhesive agent is not strictly
controlled, adverse effects that arise due to protrusion of the
adhesive agent caused by excessive application can be suppressed.
Furthermore, because the first adhesive agent reservoir portion 100
doubles as a hollow shape of the cover member 14, the molding
properties of the cover member 14 can be improved.
In the present embodiment, because the cover member side securing
surface 72 is disposed on an outer peripheral side of the first
adhesive agent reservoir portion 100, if the adhesive agent is
excessively applied, the adhesive agent that protrudes on the inner
peripheral side is accommodated in the first adhesive agent
reservoir portion 100, and the likelihood of the protruding
adhesive agent reaching the rotor 10 is low. Therefore, adverse
effects that arise due to protrusion of the adhesive agent can be
suppressed.
In the present embodiment, because the cover member side securing
surface 72 includes the chamfered surface 72a formed on an edge
adjacent to the first adhesive agent reservoir portion 100, surface
tension of the adhesive agent can be used to collect the adhesive
agent on the edge of the cover member side securing surface 72.
Therefore, the securing strength can be increased. Furthermore,
because the chamfered surfaces 98b are also formed on the edge of
the tip surfaces 98a of the radial ribs 98, surface tension of the
adhesive agent can be used to collect the adhesive agent along the
edges of the radial ribs 98. Therefore, the securing strength can
be increased. Moreover, by collecting the adhesive agent along the
edges of the radial ribs 98, the detent effect of the cover member
14 can be increased.
In the present embodiment, the resin sealing member side position
regulating surface 70 is disposed further on the counter output
side L2 (second side in the axis line L direction) than the resin
sealing member side securing surface 71, and the second adhesive
agent reservoir portion 101 is formed between the cover member side
position regulating surface 73 and the cover member side securing
surface 72, and therefore, the second adhesive agent reservoir
portion 101 can suppress the protrusion of the adhesive agent
toward the outer peripheral surface of the motor.
In the present embodiment, the cover member 14 includes a lower
annular cylindrical section 92e of the cover member cylindrical
portion 92, which is a protrusion portion that protrudes further on
the counter output side L2 (the second side in the axis line L
direction) than the cover member side position regulating surface
73 and covers the outer peripheral side of the resin sealing member
13. Therefore, the corner portion at which the outer peripheral
surface of the resin sealing member 13 and the resin sealing member
side position regulating surface 70 are connected can be protected
by the cover member 14. Moreover, if the outer peripheral surface
of the resin sealing member 13 is configured such that the entire
circumference is covered by the lower annular cylindrical section
92e of the cover member cylindrical portion 92, water and the like
can be prevented from entering between the cover member 14 and the
resin sealing member 13, yielding a waterproof effect.
In the present embodiment, because the engagement protrusion
portions 85 are provided on the outer peripheral surface of the
resin sealing member 13, and the rotation engagement portions 86
(the first rotation engagement portions 86A and the second rotation
engagement portion 86B) that engage the engagement protrusion
portions 85 by means of relative rotation of the cover member 14
with respect to the resin sealing member 13 around the axis line L
are provided on the lower annular cylindrical section 92e of the
cover member cylindrical portion 92, the adhesive agent can be
spread in the circumferential direction because the cover member 14
is relatively rotated with respect to the resin sealing member 13
when the engagement protrusion portions 85 and the rotation
engagement portions 86 engage each other.
In the present embodiment, because the cover member side securing
surface 72 and the resin sealing member side securing surface 71
are provided on the entire circumference, the adhesive agent can be
delivered over the entire circumference. Therefore, the adhesive
agent is capable of preventing water and the like from entering the
rotor 10 side, and a waterproof effect can be provided. Therefore,
an O-ring can be omitted, and costs can be reduced. Furthermore,
for example, because a rotating engagement structure is provided by
means of the rotation engagement portions 86 and the engagement
protrusion portions 85 provided between the cover member 14 and the
resin sealing member 13 as described above, the adhesive agent can
be distributed over the entire circumference due to the rotation of
the cover member 14, enabling a waterproof function to be provided
and for malfunctions such as the twisting of the O-ring caused by
rotation of the cover member 14 to be resolved.
In the present embodiment, the stator 11 includes a substantially
annular stator core 51, at least an outer peripheral section of the
output side end surface 56b of the stator core 51 is exposed from
the resin sealing member 13, and the resin sealing member side
position regulating surface 70 is provided on the outer peripheral
side of the output side end surface 56b and positioned on the same
plane as the output side end surface 56b. Therefore, the outer
peripheral side of the end surface of the stator core 51, which is
positioned so as to make contact with the mold at the time of
molding, can be covered and insulated by the cover member 14.
Modifications
(1) The cover member 14 of the present embodiment is provided with
eight radial ribs 98 and eight first adhesive agent reservoir
portions 100 between the inner annular rib 99 and the cover member
side securing surface 72, however the number, size, and positions
of the radial ribs 98 may be changed as appropriate. For example,
it is possible for just four radial ribs 98 to be provided that
pass through intermediate positions in the circumferential
direction of gate marks 102 that are adjacent to each other in the
circumferential direction. Furthermore, the number, size, and
positions of the first adhesive agent reservoir portions 100 may be
changed as appropriate. Moreover, at least an embodiment of the
present invention is also applicable to cases where the number of
gate marks 102 is not four.
(2) The cover member 14 and the resin sealing member 13 of the
present embodiment is provided with a rotating engagement structure
constituted by engagement protrusion portions 85 and rotation
engagement portions 86 (the first rotation engagement portions 86A
and the second rotation engagement portion 86B), however such a
rotating engagement structure does not have to be provided. If a
rotating engagement structure is not provided, the entire
circumference of the outer peripheral surface of the resin sealing
member 13 can be covered by the lower annular cylindrical section
92e of the cover member cylindrical portion 92. Therefore, because
thin sections of the BMC resin coating layer can be covered by the
lower annular cylindrical section 92e, the insulating effect can be
enhanced. Furthermore, the waterproof effect can be enhanced.
(3) In the cover member 14 and the resin sealing member 13 of the
present embodiment, the rotating engagement structure is
constituted by forming the engagement protrusion portions 85 on the
resin sealing member 13 and the rotation engagement portions 86 on
the cover member 14, however a mode can also be employed in which
the engagement protrusion portions are formed on the cover member
14 and the rotation engagement portions are formed on the resin
sealing member.
While the description above refers to particular embodiments of the
present invention, it will be understood that many modifications
may be made without departing from the spirit thereof. The
accompanying claims are intended to cover such modifications as
would fall within the true scope and spirit of the present
invention.
The presently disclosed embodiments are therefore to be considered
in all respects as illustrative and not restrictive, the scope of
the invention being indicated by the appended claims, rather than
the foregoing description, and all changes which come within the
meaning and range of equivalency of the claims are therefore
intended to be embraced therein.
* * * * *
References